Button Battery Lid Adapter Structure for Tolerance-Sealed Assembly
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Solution Overview
Problem
The existing manufacturing process of button batteries faces challenges due to the need for precise alignment and welding of the lid to the cup, which can result in imperfect seals and potential leakage, especially given the small dimensions and complex geometry of these batteries.
Innovation Solution
The proposed solution involves a battery design with a lid that includes an inner electrically conductive portion, an intermediate insulating portion, and a peripheral adapter portion. The peripheral adapter portion is designed to bridge the gap between the intermediate insulating portion and the sidewall of the cup-shaped bottom container, allowing for a more flexible and adaptable sealing mechanism that can accommodate various shapes and sizes of battery containers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If laser welding is used to fix the lid to the cup rim, then a sealing connection is achieved, but the manufacturing precision requirement increases due to the need for perfect alignment
Solution Approach 1:
The patent introduces an intermediate portion as a mediator component between the lid and cup. This intermediate portion includes a receiving portion that accommodates the lid and a sealing portion that contacts the cup rim, allowing the lid and cup to be connected without requiring precise direct alignment. The intermediate portion absorbs dimensional tolerances and positioning errors, enabling reliable sealing while reducing manufacturing precision requirements.
Solution Approach 2:
The lid structure is segmented into multiple functional portions: a central portion for electrical contact, a peripheral portion for mechanical support, and an intermediate portion for sealing and alignment. This segmentation allows each portion to be optimized for its specific function, with the intermediate portion specifically designed to handle alignment tolerances and positioning variations during assembly.
2Device complexity
If the lid is directly fixed to the cup rim, then the structure is simplified, but the sealing reliability decreases due to positioning difficulties
Solution Approach 1:
The intermediate portion serves as a mediator that bridges the lid and cup, providing both mechanical support and sealing functionality. It includes positioning features such as protrusions or engagement structures that ensure correct alignment during assembly, thereby maintaining sealing reliability without significantly increasing overall structural complexity.
Solution Approach 2:
The intermediate portion is designed with localized functional zones: a receiving portion with specific geometric features for lid accommodation, a sealing portion with enhanced contact surface for reliable sealing, and positioning features for alignment. This local differentiation of qualities ensures each area performs its specific function optimally while maintaining overall structural efficiency.
Data Source
AI summary
A battery (30) including: a cup-shaped bottom container (1) to accommodate an electrode assembly (4), the bottom container (1) comprising a base (2) and an upstanding sidewall (3) along an outer circumference of the base (2), a lid (10) including: an inner electrically conductive portion (11), an intermediate insulating portion (13) surrounding the inner electrically conductive portion (11), and a peripheral adapter portion (12, 15) forming or constituting an outer peripheral edge portion (26) of the lid (10) and fixable to the sidewall (3) of the bottom container (1) via the outer peripheral edge portion (26), wherein the peripheral adapter portion (12, 15) is sized, shaped and/or configured to bridge a gap between an outer edge (28) of the intermediate portion (13) and an inside perimeter of the sidewall (3).